STUDY OF MANUFACTURING AND

TESTING OF TURBO GENERATORS

Under the guidence of

M.SUDHAKAR
A.S.S.V.KOTESHWARAO
13QP1A0207
D.DINESH
13QP1A0222
D.MAHESH
13QP1A0223
D.SHANTHAN

OVERVIEW OF BHEL
The first plant of which is today known as BHEL was
established nearly 50 years ago at Bhopal & was the
genesis of the Heavy Equipment industry in India
BHEL business operations cater to core sectors of
the Indian Economy like
Power
Industry
Transportation
Transmission etc.

 BHEL presently has manufactured TurboGenerators of ratings upto 560 MW and is

in the process of going upto 660 MW.
It has also the capability to take up the
manufacture of ratings upto 1000 MW
suitable for thermal power generation.
gas based and combined cycle power
generation as-well-as for diverse industrial
applications like Paper, Sugar, Cement,
Petrochemical, Fertilizers, Rayon
Industries, etc.

INTRODUCTION
TURBOGENERATOR :
A turbo generator is a turbine directly connected to electric
generator for the generation of electricity. They are mostly
used as large capacity generator driven by steam/gas turbine.
PRINCIPLE OF OPERATION:
In case of turbo generator, Rotor winding is supplied with DC
current (through slip rings or brushless exciter) which produces
constant magnetic field.
3 phase stator winding is laid in stator core.
When generator rotor is rotated (by a turbine) magnetic flux
produced by rotor winding also rotates.
Voltage is induced in stator winding according to Faradays law.

Faradays Law:
E.M.F. (Voltage) is induced in a closed path due
to change of flux linkages and is proportional to
rate of change of flux linkages. The change in
flux linkages can be caused by change in flux in
a stationary coil or by motion of coil with
constant flux or both.
CLASSIFICATION BASED ON THE MEDIUM
USED FOR GENERATION:
Turbo generators in Thermal, nuclear, Gas
station
High speed 3000 rpm
No. of poles 2 poles
Horizontal construction
Cylindrical rotor

 Hydro generators in hydro plants

Low speed 500 to 1000 rpm
No. of poles 6 or more
Vertical construction
Salient type of rotor
COMPONENTS USED IN TURBO
GENERATOR :
The general components of a turbo
generator are

MANUFACTURING:

Stator- Stator Frame

- Stator Core
- Stator Windings
- End Covers
Rotor
- Rotor Shaft
- Rotor Windings
- Rotor Fans
Bearings

STATOR FRAME:
The stator frame is of welded steel
single piece construction.
It supports the laminated core and
winding.
It has radial and axial ribs having
adequate strength and rigidity to
minimize core vibrations and suitably
designed to ensure efficient cooling.
Guide bars are welded or bolted
inside the stator frame over which
the core is assembled.

STATOR
CORE:
The stator core is made of silicon steel with high

permeability and low hysteresis and eddy current

Losses.
The sheets are suspended in the stator frame from
insulated guide bars.

insulated electrical sheet laminations

assembly of core

STATOR WINDING CONSTRUCTION:

The winding is a double layer multi turn lap winding.
The half coils are made up of electrolytic copper
strips insulated with mica based epoxy insulation of
suitable thickness to give a long and uninterrupted
service.
Each strip is staggered to 360degrees and it passes
through all the sides of the coil. This process is
called transposition.
The purpose of transposition is to avoid the
circulation currents due to eddy current and also to
avoid corona losses.
. The straight parts of the half bar are coated with
conductive varnish to prevent corona discharges in
the slot

Phase connectors and rings

End Covers:
The end covers are the castings of
the aluminum alloy and are bolted to
the side plates of the stator frame.

Rotor

Rotor Slot

 The rotor teeth at the ends are provided with

the axial and radial holes, enabling the cooling
gas to be discharged into the air gap after,
intensive cooling of the end windings.
Rotor Winding:
The field winding consists of several series
connected coils inserted into the longitudinal
slots of the rotor body.
The coils are wound so those two poles are
obtained. The solid conductors have a
rectangular cross-section and are provided
with axial slots for radial discharge of the
cooling gas.
The individual coils of the rotor winding are
electrically series connected so that one north
and one south magnetic pole are obtained.

Rotor winding

Rotor Slot Wedge

Rotor Fan:
The generator cooling air circulated
by the two axial flow fans located on
the rotor shaft at either end.
To augment the cooling of the rotor
winding the pressure established by
the fan works in conjunction with the
air expelled from the discharge ports
along the rotor shaft.
The blades are screwed into the rotor
shaft. The blades are forged from an
aluminum alloy. Threaded root
fastening permits the blade permits

Rotor Fan

BEARINGS:
The generator rotor is supported at two-journal bearing.
The bearings consist of a bearing pedestal and bearing
shell is split into two halves to facilitate assembly.
The bearing pedestals are iron castings and the bearing
shells are the steel castings.
The bearing pedestals are providing with a spherical
seating surface and bearing shell rests into with its outer
spherical surface.
The inner surface of the bearing shell is provided with

TESTING:
To ensure that all functional requirements are
fulfilled, and to estimate the performance of
generator, the TURBO GENERATORS are required
to undergo some tests.
SHORT CIRCUIT TEST:
The machine is run at rated speed and drive
motor input voltage and current are noted and
excitation is gradually increased in steps, at 20,
40, 60, 80, 100% rated current of machine. The
short circuit characteristics is plotted from short
circuit results by selecting X-axis as field current
and Y-axis as % rated current from the Short
Circuit test, we will get copper losses.

OPEN CIRCUIT TEST :

The machine is run at rated speed

and the motor input voltage and
current are noted and excitation is
gradually increased in steps, at 20,
40, 60, 80, 90, 95, 100, 105, 110 and
120 % of rated voltage of machine.
The open circuit characteristics is
plotted from open circuit results by
selecting X-axis as field current and
Y-axis as % rated voltage.
From the open circuit test, we will
get Iron Losses.

INTER STRAND TEST:

This testing is basically done to
check any short circuit between ant
two consecutive conductors of a bar.
For this test all the bare conductors
at both the ends are separated from
each other so that they do not short
circuit.
Then a live wire is connected to a
conductor and received from it
consecutive conductor to light a
lamp.
Hence if the lamp lights up it shows

 It shows insulation failure between

the conductors, these conductors are
then replaced and bar is followed
through all the previous processes.
Similarly all the conductors are
checked for any short circuit

CONCLUSION:
The Vocational training at BHEL HYDERABAD helped
us in improving our practical knowledge and
awareness regarding Turbo Generator to a large
extent. Here we came to know about the technology
and material used in manufacturing of turbo
generators. Besides this, we also visualized the parts
involved or equipments used in the power generation.
Here we learnt about how the electrical equipments
are being manufactured and how they tackle the
various problems under different circumstances. At
least we could say that the training at BHEL
HYDERABAD is great experience for us and it really
helped us in making or developing our knowledge
about turbo generator and other equipment used in
power generation.